Hyster B416 (J2.00XM Europe) Forklift Service Repair Manual

SERVICE REPAIR J2.00XM J2.50XM J3.00XM J3.20XM Europe [B416]

1400 SRM 1223

Description

General This section has the description and repair procedures for the differential, drive axle, traction motor, and the wet disc brakes.

Description The drive unit consists of following main components (see Figure 1): • The traction motor with hollow shaft.

• Mechanical differential assembly (located on lefthand side of traction motor shaft).

• The gearbox with intermediate flange, containing the wet disc brakes.

• Main housings, containing the pistons for the wet disc brakes and the parking brake levers.

• Speed sensor and reluctor wheel (located on traction motor shaft, see Figure 8).

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WHEEL HUB GEARBOX (LH) INTERMEDIATE FLANGE (LH) MAIN HOUSING (LH) PARKING BRAKE LEVER TRACTION MOTOR

MAIN HOUSING (RH) INTERMEDIATE FLANGE (RH) GEARBOX (RH) SPEED SENSOR DIFFERENTIAL ASSEMBLY

Figure 1. Drive Unit 1

Description

1400 SRM 1223

The drive unit assembly is fastened to the frame of the lift truck by the frame mounts of the main housings. See Figure 2.

The traction motor is mounted in between the two main housings. The traction motor generates the power to the differential assembly. See Figure 4.

The mast is mounted on the J-hook mountings of the main housings of the drive unit. See Figure 3.

1. FRAME MOUNTS Figure 2. Drive Unit Frame Mounts

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Description

1. J-HOOK MOUNTINGS Figure 3. Mast Mounting Hooks

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WHEEL HUB PLANETARY GEAR INPUT SHAFT (RH) DRIVE GEAR AXLE SHAFT

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TRACTION MOTOR SHAFT DIFFERENTIAL ASSEMBLY DRIVE GEAR INPUT SHAFT (LH) SUN PINION

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DRIVEN GEAR BRAKE DISC PACK DISC PUSHER PISTON PARK BRAKE LEVER

Figure 4. Drive Unit

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Description

1400 SRM 1223

The differential then transfers the power through the axle shaft to the input shafts located in the intermediate flange assemblies. The input shaft drive gears transfer the power to the driven gears. The driven gears then transfer the power to the sun pinion. See Figure 5.

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PLANETARY CARRIER PLANETARY GEARS RING GEAR WHEEL HUB Figure 6. Planetary Gears

The wet brake discs are mounted on the intermediate flanges. The piston, which is located in the main housing (one in each main housing), is activated when the brake pedal is applied. The piston presses against the disc pusher which compresses the brake friction discs and steel discs which causes the braking. See Figure 7.

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DRIVE GEAR INTERMEDIATE FLANGE INPUT SHAFT AXLE SHAFT DRIVEN GEAR SUN PINION

Figure 5. Drive Gear, Driven Gear, and Sun Pinion The sun pinion then transfers the power to the planetary gears and planetary carrier which then engages the wheel hubs. See Figure 6.

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The parking brake levers press against the back of the piston which forces the piston to press against the disc pusher to compress the brakes friction discs and steel discs to mechanically apply the parking brake.

The speed sensor is mounted on the main housing on the right-hand side of the drive unit. The reluctor wheel is mounted on the traction motor shaft on the right-hand side of the traction motor. The speed sensor is a hall effect sensor which reads the variation in its magnetic field when a tooth of the reluctor wheel passes the sensor. See Figure 8.

1400 SRM 1223

Wet Disc Brake Repair

1. INTERMEDIATE FLANGE 2. DISC PUSHER 3. BRAKE DISC PACK

1. SPEED SENSOR 2. RELUCTOR WHEEL

Figure 7. Brake Disc Pack

Figure 8. Speed Sensor and Reluctor Wheel

Wet Disc Brake Repair WET DISC BRAKES For replacement of the pistons and piston seals, refer to the section Main Housing Repair.

Remove STEP 1.

Remove the gearbox. Refer to the section Gearbox Replacement.

STEP 2.

Press down on the disc pusher device and remove the retaining rings from the studs.

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Wet Disc Brake Repair

1400 SRM 1223

STEP 3.

Remove the disc pusher device from the studs.

1. DISC PUSHER DEVICE 2. STUDS

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Wet Disc Brake Repair

STEP 4.

Remove the springs from the studs.

If necessary, remove the studs.

1. STUDS 2. SPRINGS STEP 5.

Note the position of the notches on the steel discs for correct positioning during assembly.

Remove one steel disc.

1. STEEL DISC 2. NOTCH

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Wet Disc Brake Repair

1400 SRM 1223

STEP 6.

Remove the one friction disc.

1. FRICTION DISC STEP 7.

Remove four springs/spacers.

1. SPRINGS/SPACERS

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1400 SRM 1223

Wet Disc Brake Repair

STEP 8.

Repeat STEP 5 through STEP 7 until the last steel disc is removed.

STEP 9.

Remove the aluminum reaction disc.

Inspect 1. Inspect the brake friction discs and brake steel discs. The discs must be measured as a pack (6 steel discs and 5 friction discs) to determine if the discs need replaced. Replace discs as a pack when the thickness is less than 23 mm (0.91 in.).

A new disc pack will have a thickness of 23.95 to

24.45 mm (0.94 to 0.96 in.). When replacing the disc pack, all springs must also be replaced.

2. Inspect the aluminum reaction disc. Replace the aluminum reaction disc when the thickness is equal or less than 4.5 mm (0.18 in.). A new aluminum reaction disc will have a thickness of 4.95 to 5.05 mm (0.195 to 0.199 in.).

Install STEP 1.

If removed, install the four pins.

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Wet Disc Brake Repair

1400 SRM 1223

STEP 2.

If removed, apply LoctiteŽ 242 to the studs and install the studs. Tighten the studs to 2 N•m (17.7 lbf in).

STEP 3.

Install the aluminum reaction disc.

NOTE: The first and last disc installed must be a smooth steel disc.

STEP 4.

Align the notch of the steel disc as noted during disassembly.

Install one steel disc.

1. NOTCH

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1400 SRM 1223

Wet Disc Brake Repair

STEP 5.

Install one friction disc.

STEP 6.

Install four springs/spacers.

STEP 7.

Repeat STEP 4 through STEP 6 until six steel discs and five frictions discs have been installed.

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Wet Disc Brake Repair

1400 SRM 1223

STEP 8.

Install the springs onto the studs.

1. STUDS 2. SPRINGS

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1400 SRM 1223

Wet Disc Brake Repair

STEP 9.

Install the disc pusher device onto the studs.

1. DISC PUSHER DEVICE 2. STUDS

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Gearbox Replacement

1400 SRM 1223

STEP 10.

Press down on the disc pusher device and install the retaining rings into the seats on the studs.

STEP 11.

Install the gearbox. Refer to the section Gearbox Replacement.

Gearbox Replacement REMOVE Gearbox Removal WARNING When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, one-piece units.

1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck.

5. Remove the wheel from the wheel hub of the gearbox being replaced.

6. Remove the gearbox oil fill plug. See Figure 9.

7. Remove the gearbox magnetic drain plug to drain the oil from the gearbox into a suitable container.

See Figure 9.

8. Remove the brake oil fill/breather plug from main housing. See Figure 9.

9. Remove the brake oil drain plug to drain the oil from the main housing into a suitable container.

See Figure 9.

2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability.

10. Place a sling connected to an overhead lift around the gearbox and wheel hub assembly and apply light tension to the sling.

3. Remove the mast assembly as described in the section Mast Repairs, 2, 3, and 4-Stage Masts 4000 SRM 1148.

11. Remove the socket-head screws retaining the gearbox to the main housing. Note the positions of the short and long socket-head screws for when the gearbox is installed. See Figure 10.

4. Disconnect the battery connector.

12. Remove the gearbox and wheel hub assembly.

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1400 SRM 1223

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BRAKE OIL FILL/BREATHER PLUG GEARBOX OIL FILL PLUG GEARBOX OIL DRAIN PLUG (MAGNETIC) BRAKE OIL DRAIN PLUG

Gearbox Replacement

1. M8 SOCKET-HEAD SCREWS, 3 EACH 2. M12 X 1.75 X 70 MM LONG SOCKET-HEAD SCREWS, 11 EACH 3. M12 X 1.75 X 40 MM SHORT SOCKET-HEAD SCREWS, 2 EACH Figure 10. Gearbox Removal/Installation

Figure 9. Oil Refill and Drain Plugs

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Gearbox Replacement

Intermediate Flange Removal STEP 1.

Remove the brake discs and friction plates. Refer to the section Wet Disc Brake Repair.

STEP 2.

For the left-hand side gearbox only, remove the spacer from the input shaft.

STEP 3.

Remove the socket-head screws used to retain the intermediate flange to the gearbox housing.

Insert a prybar into the pry slots between the intermediate flange and the gearbox housing and pry upwards to break the seal between the flange and housing.

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1400 SRM 1223

1400 SRM 1223

Gearbox Replacement

1. SOCKET-HEAD SCREWS 2. PRY SLOTS STEP 4.

Remove the intermediate flange assembly from the gearbox housing.

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Gearbox Replacement

1400 SRM 1223

DISASSEMBLE The gearbox is to be replaced as an assembly and is not disassembled.

Intermediate Flange NOTE: If the inner ring for the needle bearing is being replaced, the needle bearing in the gearbox housing must be replaced.

STEP 1.

Using an appropriate puller, remove the needle bearing from the gearbox housing.

1. GEARBOX 2. NEEDLE BEARING STEP 2.

Remove the snap ring retaining the input shaft into the intermediate flange.

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1400 SRM 1223

Gearbox Replacement

1. SNAP RING 2. INPUT SHAFT STEP 3.

Using plastic or hard rubber hammer, tap the input shaft, on the gear side, with drive gear and bearing out of the intermediate flange.

1. INTERMEDIATE FLANGE 2. INPUT SHAFT ASSEMBLY

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Gearbox Replacement STEP 4.

Remove the retaining ring from the input shaft.

STEP 5.

Place a cylinder on the press workbench as shown.

Cylinder dimensions: • Inside diameter - 41 mm (1.61 in.)

• Outside diameter - 62 mm (2.44 in.)

• Height - minimum 130 mm (5.12 in.)

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1400 SRM 1223

1400 SRM 1223

Gearbox Replacement

STEP 6.

Place the input shaft assembly with drive gear side up on the cylinder.

Place a cylinder (solid shaft) on top of the input shaft and use a press to press the input shaft out of the needle bearing inner ring, the drive gear, and the bearing.

Cylinder dimensions: • Diameter - maximum 18.5 mm (0.73 in.)

• Height - minimum 45 mm (1.77 in.)

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CYLINDER NEEDLE BEARING INNER RING DRIVE GEAR BEARING CYLINDER WORKBENCH

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NEEDLE BEARING INNER RING DRIVE GEAR BEARING SQUARE KEY INPUT SHAFT

STEP 7.

Remove the square key from the input shaft.

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